Electrode wire for electro-discharge machining and method for manufacturing the same

ABSTRACT

Disclosed are an electrode wire for electro-discharge machining and a method for manufacturing the same. The electrode wire includes a core wire including a first metal including copper, a first alloy layer formed at a boundary region between the core wire and a second metal plated on an outer surface of the core wire due to mutual diffusion between the core wire and the second metal, and a second alloy layer formed due to diffusion of the first metal to the second metal. A core wire material is erupted onto a surface of the electrode wire for electro-discharge machining, which includes the core wire, the first alloy layer, and the second alloy layer, along cracks appearing on the second alloy layer, so that a plurality of grains are formed on the surface of the electrode wire.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of co-pending application Ser. No.13/442,615, filed Apr. 9, 2012, which claims priority under 35 U.S.C.§119 to Korean Patent Application No. 10-2011-0040757, filed Apr. 29,2011. The entire contents of the above applications are herebyincorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an electrode wire for electro-dischargemachining and a method for manufacturing the same. In more particular,the present invention relates to an electrode wire for electro-dischargemachining and a method for manufacturing the same, capable of reducingmachining particles generated when an electrode wire is subject to theelectro-discharge machining and improving the machining speed and thesurface roughness of a workpiece.

2. Description of the Related Art

In general, as shown in FIG. 1, according to an electro-dischargemachining scheme employing an electrode wire 2, the electrode wire 2 isinserted into a workpiece 1 through a start hole 7 which has beenpreviously perforated through the workpiece 1. A high-frequency voltageis applied between the electrode wire 2 and an inner wall surface of thestart hole 7 while the electrode wire 2 is being continuously insertedinto the workpiece 1 in the perforation direction of the start hole 7,thereby generating arc between the electrode wire 2 and the inner wallsurface of the start hole 7, so that the workpiece 1 is melted. Then,melts are removed by using a machining liquid and the instantaneousvaporization power between the electrode wire 2 and the workpiece 1, sothat the workpiece 1 can be machined in a desired shape.

According to the electro-discharge machining principle, anelectro-discharge machine includes a power supply, a wire transferringunit, a workpiece transferring unit, and a machining liquid circulatingunit.

In general, as indicated by the arrow in FIG. 1, the workpiecetransferring unit moves perpendicularly to the electrode wire 2. Afterthe electrode wire 2 continuously reeled out of a supply reel 3 is hangon guide rollers 5 and 5′ provided at both end portions of the workpiece1, the electrode wire 2 is wound around a winding reel 4.

In this case, a high frequency-voltage is applied between the workpiece1 and the electrode wire 2 through the power supply 6 to perform acutting machining process, and deionized water is supplied to amachining region as a machining liquid in order to discharge heatemitted in the cutting machining process. The efficiency of theelectro-discharge machining, especially, the machining speed,significantly depends on machining parameters such as the feeding speedof the machining liquid, machining current density, and the shape andfrequency of the machining voltage, and the efficiency of theelectro-discharge machining can be improved by adjusting the machiningparameters.

Pure copper has been used in a conventional technology since the purecopper has high electrical conductivity and facilities a fine wireprocess due to a high elongation property. However, since a pure copperline represents a low tensile strength in the electro-dischargemachining, the pure copper may be easily disconnected. In addition, ahigh tensile strength cannot be applied to the copper line, so thatvibration of the electrode wire 2 cannot be controlled, therebyresulting in an inferior machining accuracy.

In addition, the copper wire represents a relatively slower machiningspeed. Therefore, a high strength wire such as a molybdenum wire or atungsten wire has been used for a special application of high machiningprecision. In addition, a brass electrode wire, such as a brass wireincluding copper and zinc in a weight ratio of 65%:35%, has beendeveloped for the general purpose of wire electro-discharge machining.

When comparing with a pure copper wire, the brass electrode wire has atensile strength which is at least twice greater than the tensilestrength of the copper wire, and more improves discharge stability andinstantaneous vaporization power due to zinc which is an alloy componentof the brass electrode wire. Accordingly, when comparing with the purecopper wire, the brass electrode wire improves the machining speed andthe machining precision.

In addition, as the electro-discharge machining scheme has beenextensively used, the demand for the improvement of a tensile strengthand the machining speed is increased. Accordingly, an advanced brasselectrode wire has been developed by adding a small amount of Al, Si,and the like to the brass electrode wire, so that the tensile strengthand the machining speed of the brass electrode wire can be improved.

Meanwhile, as zinc content is increased in a brass alloy, the machiningspeed may be increased. However, if the zinc content is more than 40weight % in the brass alloy, a weak brittle phase β is formed, so that adrawing process may be difficult when a fine wire is formed.

In order to solve the above problem, the inventor of the presentinvention has suggested the structure of an electrode wire in KoreaPatent Registration No. 10-518727, in which the electrode wire includesa core wire including a first metal including copper, an alloy layer,which is formed from an outer portion of the core wire toward the centerof the core wire by diffusing the component of a second metal to thefirst metal through the mutual diffusion reaction between the first andsecond metals at the boundary region of the core wire, an alloy platedlayer, which is formed on the core wire by diffusing the component ofthe first metal to the second metal through the mutual diffusionreaction between the first and second metals, and a plating layer, whichis formed on the alloy plated layer and includes the second metal havinga vaporization temperature lower than that of the first metalconstituting the core wire. In this case, the alloy plated layer isformed on the core wire through the mutual diffusion reaction betweenthe first and second metals, so that the alloy plated layer representsthe highest hardness and the lowest elongate percentage among thelayers. In addition, the alloy plated layer and the plating layer havecracks appearing perpendicularly to the longitudinal direction of theelectrode wire.

In addition, the inventor of the present invention has suggested thestructure of an electrode wire including a core wire including a firstmetal including copper, an alloy layer, which is formed from an outerportion of the core wire toward the center of the core wire by diffusingthe component of a second metal to the first metal through the mutualdiffusion reaction between the first and second metals at the boundaryregion of the core wire, and an alloy plated layer, which is formed onthe core wire by diffusing the component of the first metal to thesecond metal through the mutual diffusion reaction between the first andsecond metals. In this case, the alloy plated layer is formed on thecore wire through the mutual diffusion reaction between the first metaland the second metal having a vaporization temperature lower than thatof the first metal to represent the hardness higher than that of thecore wire and the elongation percentage lower than that of the corewire. The alloy plated layer has cracks appearing perpendicularly to thelongitudinal direction of the electrode wire. The first metal includescopper, brass, or a copper alloy, and the second metal includes zinc,aluminum, tin, or the alloy thereof.

Further, the inventor of the present invention has suggested a methodfor manufacturing an electrode wire for electro-discharge machining inKorea Patent Registration No. 10-518731, in which the method includespreparing an intermediate wire rode, which serves as a core wire,includes a first metal including copper, and has a first diameter,forming an alloy layer, which represents the hardness higher than thoseof the first and second metals and the elongation percentage lower thanthose of the first and second metals, on an outer portion of the corewire through the mutual diffusion reaction between the first and secondmetals by passing the core wire including the first metal through aplating bath containing the second metal melted therein and having avaporization temperature lower than that of the first metal and forminga plating layer including the second metal on the alloy layer, allowingcracks to appear on the alloy layer and the plating layer due to thehigher hardness and the lower elongation percentage of the alloy layerby drawing the intermediate wire rod having the alloy and plating layersso that the intermediate wire rod has a second diameter, and stabilizinga mechanical characteristic of a fine wire by performing a heattreatment process with respect to the fine wire having the cracks.

In order to form the alloy and plating layers on the core wire, the corewire is passed through the plating bath for one second to ten seconds ata temperature of about 400° C. to about 500° C. The first metal includescopper, brass, or a copper alloy, and the second metal includes zinc,aluminum, tin or the alloy thereof.

In addition, the inventor of the present invention has suggested amethod for manufacturing an electrode wire for electro-dischargemachining in Korea Patent Registration No. 10-518733, in which themethod includes preparing an intermediate wire rode, which serves as acore wire, includes a first metal including copper, and has a firstdiameter, forming an alloy plated layer, which represents the hardnesshigher than those of the first and second metals and the elongationpercentage lower than those of the first and second metals, on an outerportion of the core wire through the mutual diffusion reaction betweenthe first and second metals by passing the core wire including the firstmetal through a plating bath containing the second metal melted thereinand having a vaporization temperature lower than that of the firstmetal, allowing cracks to appear on the alloy plated layer due to thehigher hardness and the lower elongation percentage of the alloy layerby drawing the intermediate wire rod having the alloy plated layer sothat the intermediate wire rod has a second diameter, and stabilizing amechanical characteristic of a fine wire by performing a heat treatmentprocess with respect to the fine wire having the cracks.

According to the related arts, an electrode wire having an alloy layerincluding copper-zinc grain fragments is formed through the mutualdiffusion reaction with a core wire metal including copper performed dueto the melted zinc and applied heat, so that the machining speed can beimproved. However, when performing an elongation process for a brasscore wire representing 510N, the brass core wire is strengthened, sothat the brass core wire may be easily fragmented, thereby producing agreat amount of machining particles in electro-discharge machining.

CITED REFERENCES

-   Patent 1: Korea Patent Registration No. 10-518727-   Patent 2: Korea Patent Registration No. 10-518731-   Patent 3: Korea Patent Registration No. 10-518733

SUMMARY OF THE INVENTION

Accordingly, the present invention has been made keeping in mind theabove problems occurring in the prior art, and an object of the presentinvention is to manufacture a core wire representing the higherelongation percentage and the lower tensile strength by adjusting a heattreatment temperature in a dip-plating process, in detail, by increasingthe heat treatment temperature.

Another object of the present invention is to provide an electrode wirefor electro-discharge machining, capable of significantly reducingmachining particles while maintaining the machining speed by pushing themanufactured core wire representing the lower tensile strength, that is,the softer brass core wire onto a zinc-copper alloy surface along cracksof the alloy layer due to the pressure generated in an elongationprocess as if lava, thereby surrounding or covering zinc-copper alloygrain fragments.

Still another object of the present invention is to make grain fragmentshaving lengths, which are at least twice greater than widths thereof, bypushing the softer core wire material onto a surface of an electrodewire along cracks when performing elongation and drawing processes, inwhich the cracks are previously made on the core wire materialconstituting the electrode wire for electro-discharge machining in adirection perpendicular to a longitudinal direction of the core wirematerial by forcibly curving or twisting the softer brass core wireplated with zinc in at least one of up, down, left, and right directionsbefore the elongation and drawing processes are performed.

Still yet another object of the present invention is to provide anelectrode wire for electro-discharge machining, capable of increasingthe surface roughness of a workpiece and preventing machining particlesof the electrode wire while rapidly maintaining the machining speed whenperforming the electro-discharge machining by forming grain fragmentshaving lengths, which are at least twice greater than widths thereof, onthe surface of the electrode wire in a direction perpendicular to alongitudinal direction of a core wire material.

Still yet another object of the present invention is to provide aneco-friendly electrode wire capable of improving the precision inelectro-discharge machining.

To accomplish these objects, according to one aspect of the presentinvention, there is provided an electrode wire for electro-dischargemachining including a core wire including a first metal includingcopper, a first alloy layer formed at a boundary region between the corewire and a second metal plated on an outer surface of the core wire dueto mutual diffusion between the core wire and the second metal, and asecond alloy layer formed at an outer portion of the first alloy layerdue to diffusion of the first metal to the second metal. A core wirematerial is erupted onto a surface of the electrode wire forelectro-discharge machining, which includes at least the core wire, thefirst alloy layer, and the second alloy layer, along cracks appearing onthe second alloy layer, so that a plurality of grains are formed on thesurface of the electrode wire. The grain including at least the corewire material and a second alloy material is distributed onto thesurface of the electrode wire for electro-discharge machining.

In addition, the core wire material is erupted together with a firstalloy material, so that the grain including the core wire material, thefirst alloy material, and the second alloy material is distributed onthe surface of the electrode wire for electro-discharge machining.

In addition, the first metal includes one selected from the groupconsisting of copper, brass, and a copper alloy, and the second metalincludes one selected from the group consisting of zinc, aluminum, tin,and an alloy thereof.

In addition, the grain including at least the second alloy material issurrounded by the core wire material.

In addition, the grain including the core wire material is arranged in adirection substantially perpendicular to a longitudinal direction of theelectrode wire for electro-discharge machining, and has a length twiceor ten times greater than a width of the grain.

According to one aspect of the present invention, there is provided Amethod of manufacturing an electrode wire for electro-dischargemachining including preparing an intermediate wire rod, which includes afirst metal and has a first diameter, as a core wire, plating the corewire with a second metal, performing a heat treatment process to makethe plated core wire representing tensile strength of about 500N/mm2 orless and elongation percentage of 5 or more and to form a first alloylayer in at least a boundary region between the core wire and the secondmetal due to mutual diffusion between the core wire and the second metaland to form a second alloy layer on an outer portion of the first alloylayer through diffusion of the first metal to the second metal, andforming a grain including at least a core wire material and a secondalloy material on a surface of the electrode wire for electro-dischargemachining by erupting the core wire material through a crack appearingon the second alloy layer when performing a fine wire process of makingthe electrode wire for electro-discharge machining which includes thefirst alloy layer, the second alloy layer, and the core wire and has asecond diameter.

In addition, in the forming of the grain on the surface of the electrodewire for electro-discharge machining, the core wire material is eruptedtogether with a first alloy material, so that the grain including thecore wire material, the first alloy material, and the second alloymaterial is formed.

In addition, the core wire is plated with the second metal through oneof an electroplating scheme, a dip-plating scheme, and a chemicalplating scheme.

In addition, the core wire is plated with the second metal through thedip-plating scheme, and the heat treatment process is performed bydipping the core wire into a plating bath having an entrance temperatureof about 550° C. to about 700° C. and an exit temperature of about 420°C. to about 500° C. within time of about 1 second to about 10 seconds.

In addition, before the electrode wire for electro-discharge machiningis drawn to have a second diameter in the forming of the grain, theelectrode wire for electro-discharge machining is forcibly twisted in atleast one of up, down, left, and right directions.

In addition, the first metal may include pure copper, or brass including63 weight % to 67 weight % of copper and 33 weight % to 37 weight % ofzinc. The second metal includes one selected from the group consistingof zinc, aluminum, tin, and an alloy thereof.

In particular, according to the present invention, if the dip-platingprocess is employed, the core wire including the first metal and havingthe first diameter is plated with the second metal at a predeterminedthickness. In order to allow the plated core wire to represent thetensile strength of about 500N/mm2 or less and the elongation percentageof about 5% or more, the plating process may be performed again in astate that the temperature of the plating bath having the same size isincreased, or the dipping and passing time of the core wire in theplating bath may be prolonged. Accordingly, the winding speed of theintermediate wire rod passed through the plating bath may be controlled.

For example, if the winding speed of the intermediate wire rod isquickly increased, the length or the temperature of the plating bathmust be increased.

The conditions related to the winding speed, the length of the platingbath, and the temperature form the first alloy layer of about 1 μm toabout 3 μm and the second alloy layer of about 3 on to about 10 μm onthe core wire plated with zinc, that is, the intermediate wire rodhaving the first diameter, so that the intermediate wire rod canrepresent the tensile strength of about 500N/mm2 or less and theelongation percentage of about 5% or more.

In this case, the first alloy layer is formed from the outer portion ofthe core wire to the center of the core wire by diffusing the secondmetallic component to the first metal due to the mutual diffusionreaction between the first and second metals at the boundary region ofthe core intermediate wire rod. The second alloy layer having thevaporization temperature lower than that of the first metal of the corewire and higher than that of the second metal is formed by diffusing thefirst metallic component to the second metal due to the mutual diffusionreaction between the first and second metals at the boundary region ofthe first alloy layer.

According to the method for manufacturing the electrode wire, in orderto stabilize the mechanical characteristic of the electrode wire, a heattreatment process is additionally performed with respect to theelectrode wire for electro-discharge machining that has beenmanufactured as a fine wire having the second diameter.

As described above, according to the electrode wire forelectro-discharge machining of the present invention, a materialconstituting a core wire is erupted onto the surface of the electrodewire along cracks formed in an alloy layer of the electrode wire as iflava, so that a plurality of grains are formed on the surface of theelectrode wire. In addition, the grains of the core wire material formedon the surface of the electrode wire for electro-discharge machiningsurround at least grains of a second alloy layer, thereby preventingbroken grains from getting out of the surface, so that machiningparticles can be reduced when the electro-discharge machining isperformed. In addition, the efficiency of the electro-dischargemachining can be improved, so that the machining speed can be increased.

If the generation of the machining particles is prevented in theelectro-discharge machining, discharge can be prevented from beingperformed again due to the machining particles when performing theelectro-discharge machining, and the machining particles can beprevented from being filled in a diamond guide dice hole through whichthe electrode wire is passed.

In particular, according to the present invention, since the grains arearranged with lengths, which are about two times to about ten timesgreater than the widths thereof, in a direction substantiallyperpendicular to a longitudinal direction of the electrode wire, thesurface roughness of a workpiece and the machining speed for theworkpiece can be maximized.

The machining speed for the workpiece is improved. This is because thesofter core wire is erupted onto the surface of the electrode wire alongcracks and exposed, so that grains are formed to surround the secondalloy layer, thereby reducing machining particles derived from theelectrode wire and allowing the second alloy layer having a vaporizationtemperature lower than that of the first metal to increase the explosionpower of thermal energy in discharge.

Meanwhile, since the electrode wire for electro-discharge machining hasa uniform circumferential surface without protrusions, a bad influenceis not exerted on the precision of the electro-discharge machining. Inaddition, the cooling efficiency can be improved when performing theelectro-discharge machining due to cracks formed around the grains, andfragments resulting from the electro-discharge machining can be easilyremoved due to the lower vaporization temperature, thereby obtainingsuperior detergency effect and improving the surface roughness of theelectrode wire.

In particular, stress is applied to an intermediate wire rod before anelongation process is performed as described in embodiments 2 and 4 ofthe present invention, so that grains having lengths, which are abouttwo times to about ten times greater than widths thereof, are arrangedin a direction substantially perpendicular to a longitudinal directionof the electrode wire. Accordingly, both the machining speed and thesurface roughness can be improved.

The grains are formed through the manufacturing method in embodiments 2and 4, so that a wire is supplied from an upper portion of a workpieceto a lower portion of the workpiece at a speed of at most 15,000 mm/min.In addition, for example, the workpiece having the thickness of about 40mm may be machined at a machining speed of about 3 mm/min to about 4mm/min.

The reasons for the above effects are that a plurality of grain patternsarranged in the perpendicular direction are subject to theelectro-discharge machining as if multiple blades move down whilesmoothing the surface of a workpiece.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and other advantages of thepresent invention will be more clearly understood from the followingdetailed description when taken in conjunction with the accompanyingdrawings, in which:

FIG. 1 is a schematic view showing the technical configuration and theprinciple of an electro-discharge machine according to the related art;

FIG. 2 is a view showing a method for manufacturing an electrode wirefor electro-discharge machining according to the present invention;

FIG. 3 is a photograph showing a product of the electrode wire for theelectro-discharge machining according to a first embodiment of thepresent invention;

FIG. 4 is a photograph showing a product of an electrode wire forelectro-discharge machining according to a second embodiment of thepresent invention;

FIG. 5 is a photograph showing a product of an electrode wire forelectro-discharge machining according to a third embodiment of thepresent invention;

FIG. 6 is a photograph showing a product of an electrode wire forelectro-discharge machining according to a fourth embodiment of thepresent invention;

FIG. 7 is a photograph showing cracks appearing when stress is appliedto an intermediate wire rod throughout the whole steps of an elongationprocess according to the second embodiment of the present invention;

FIG. 8 is a photograph showing cracks appearing when stress is appliedto an intermediate wire rod throughout the whole steps of an elongationprocess according to the fourth embodiment of the present invention;

FIG. 9 is a sectional view schematically showing the product accordingto the first and third embodiments of the present invention; and

FIG. 10 is a sectional view schematically showing the product accordingto the second and fourth embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter, the structure of an electrode wire for electro-dischargemachining according to the present invention, the technicalconfiguration in a method for manufacturing the electrode wire accordingto the present invention, and effects of the present invention will bedescribed in detail with reference to FIGS. 2 to 10.

Referring to FIG. 2, a core wire 12 including brass including about 65weight % of copper and about 35 weight % of zinc is provided with adiameter in the range of about 0.9 nm to about 1.2 nm.

The core wire 12 is dipped into a plating bath 10 containing melted zinchaving a vaporization temperature lower than that of brass for apredetermined time and passed through the plating bath 10, so that themelted zinc is plated on an outer portion of the core wire 12.

In particular, the entrance temperature of the plating bath 10 isadjusted to the range of about 550° C. to about 700° C., and the exittemperature of the plating bath 10 is adjusted to the range of about420° C. to about 500° C. In addition, the core wire 12 is dipped intothe plating bath 10 and passed through the plating bath 10 within timeof about 1 second to about 10 seconds, thereby adjusting the tensilestrength of the core wire 12 to the tensile strength of 500N/mm2 or lessand adjusting the elongation percentage of about 5 or more.

In this case, the core wire 12 is provided on the interfacial surfacethereof with an alloy layer representing higher hardness and the lowerelongation percentage due to the diffusion reaction between zinc, whichis melted in the plating bath 10, and brass when comparing with a corewire including only brass.

The core wire 12 plated with the alloy layer while being passed throughthe plating bath 10 under the above conditions is drawn by a drawingunit 14, so that the core wire 12 obtains a proper diameter, forexample, the diameter of about 0.07 mm to about 0.35 mm.

The core wire 12 including brass, which is plated with zinc at athickness of about 3 μm to about 10 μm through an electroplating schemeor a chemical plating scheme other than the scheme of passing the corewire 12 through the plating bath 10, may be subject to a heat treatmentprocess at a speed of about 100 m/min to about 600 m/min under thevoltage of about 10V to about 60V, so that the zinc plated core wire 12including brass can represent the tensile strength of about 500N/mm2 orless and the elongation percentage of about 5 or more.

A copper component of the core wire 12 is diffused to the zinc platedlayer to form a second alloy layer at an outer portion of a first alloylayer which is interposed between the core wire 12 and the zinc platedlayer. Since the second alloy layer represents the highest hardness andthe lowest tensile strength, a great amount of cracks appear on thesecond alloy layer due to the difference in the hardness and theelongation percentage between the second alloy layer and other layerswhen the second alloy layer is drawn. Accordingly, softer brassconstituting the core wire 12 is erupted onto the surface of the secondalloy layer as if lava and distributed onto the surface of the secondalloy layer.

The mechanical properties of the fine wire can be more stabilizedthrough the heat treatment process.

FIGS. 3 and 5 are photographs showing the surface of the drawn electrodewire for electro-discharge machining, and FIG. 9 is a sectional viewschematically showing the electrode wire for electro-discharge machiningof FIGS. 3 and 5.

Referring to FIG. 9, a core wire material of brass and the alloymaterial are significantly distributed onto the surface of the electrodewire for the electro-discharge machining. The core wire material and thealloy material are erupted upward as if lava along cracks, so that thecore wire material and alloy material are distributed on the surface ofthe electrode wire together with grains of the alloy layer or the alloymaterial is surrounded by the core wire material.

A twist unit 33 is additionally provided between a roller 16′ and thedrawing unit 14 to make the intermediate wire rod curved in at least oneof up, down, left, and right directions, or make the intermediate wirerod twisted when drawing the core wire 12 in order to finely form thecore wire 12 having the first and second alloy layers, thereby morecausing cracks on the intermediate wire rod, so that softer brass iserupted onto the surface of the zinc plated layer through the cracks toform grains in a circumferential direction of the intermediate wire rod.

If stress is applied to the intermediate wire rod constituting the corewire 12 before a fine wire process is performed, grains having a longlength may be arranged on the surface of the intermediate wire rod inthe circumferential direction of the intermediate wire rod. The lengthof each grain is about twice to ten times greater than the width of thegrain.

FIGS. 4 and 6 are photographs showing the surface of the electrode wirefor electro-discharge machining which is finely drawn after stress suchas curving is applied to the intermediate wire rod for the electrodewire before the fine wire process is formed. FIG. 10 is a sectional viewschematically showing the electrode wire for electro-discharge machiningof FIGS. 4 and 6.

Referring to FIG. 10, a core wire material of brass is significantlydistributed on the surface of the electrode wire for theelectro-discharge machining, and brass grains are arranged on thesurface of the electrode wire in the circumferential direction whileforming a predetermined pattern.

The grains including the core wire material are greatly distributed onthe surface of the electrode wire. This is because conditions of theheat treatment process for the material constituting the core wire 12are properly adjusted, so that the tensile strength becomes about500N/mm2 or less, and the elongation percentage becomes about 5% or morethrough the plating process/heat treatment process, and the intermediatewire rod is curved in a predetermined direction or stressed due to twistby the twist unit 33 before the fine wire process (elongation process)is performed.

The electrode wire for electro-discharge machining according to thepresent invention includes the core wire 12 including brass, the firstalloy layer 22 formed at the boundary region of the core wire 12 bymutually diffusing zinc and a material of the core wire to each other,and a second alloy layer 23 formed at an outer portion of the firstalloy layer 22 by diffusing the material constituting the core wire tothe zinc layer.

The material constituting the core wire 12 may include metal includingcopper, for example, brass. The core wire 12 made of the materialsatisfies the conditions of the electrical conductivity and themechanical strength required as an electrode wire. The second alloylayer 23 includes a material, such as zinc, representing a lower meltingpoint and a lower vaporization temperature as compared with those of amaterial constituting the core wire 12 to protect the core wire 12 andto improve the machining speed when the electro-discharge machining isperformed.

In addition, since the second alloy layer 23 has a greater amount ofcracks and grains, the second alloy layer 23 can obtain a cooling speedsuperior to that of the conventional electrode wire. The properties ofmaterials used in a plating process must desirably represent a lowermelting point and a lower vaporization temperature as compared withthose of the second alloy layer 23. The materials must be metal which isdip-plated on the metal of the core wire 12 including copper or brassand forms an alloy layer representing higher hardness through thediffusion reaction with copper in the dip-plating process. The metalincludes zinc, aluminum, and tin.

Therefore, when the zinc-alloy intermediate wire rod is finely drawn toform the electrode wire for electro-discharge machining, the alloy layermay be easily cracked due to the difference in the elongation percentagebetween the core wire 12 and the alloy layer.

As shown in FIGS. 3 and 6, since the softer material constituting thecore wire 12 softly surrounds the alloy layer representing a greaterstrength between the cracks, the probability of generating machiningparticles from the core wire and the alloy layer constituting theelectrode wire is reduced in the electro-discharge machining process, Inaddition, by-products such as fragments of the workpiece may be absorbedand removed through the cracks between boundary regions of the grains.Accordingly, the detergency effect can be more increased when comparingwith the conventional electrode wire for electro-discharge machining.

Embodiment 1

A core wire (including the first metal) having a diameter of about 0.9mm, which is a brass wire (i.e., core wire including the first metal)having a compositional ratio of about 65 weight % of copper and about 35weight % of zinc, is prepared as an intermediate wire rod.

A zinc dip-plating process is performed with respect to the core wire byusing zinc which is the second metal.

The core wire used in the zinc dip-plating process is passed through analkaline degreasing bath so that the core wire is cleaned. Then, afterthe core wire is subject to an acidic washing process, the core wire iscleaned again and passed through an ammonium chloride flux bath.

When the wire including the first metal that has been subject to theflux treatment is dipped into an zinc dip-plating bath of the secondmetal and passed through the plating bath so that the wire is platedwith zinc, the intermediate wire rod for the core wire 12 is dipped intothe plating bath for one second to ten seconds and passed through theplating bath in a state that the temperature of a bath entrance ismaintained in the range of about 555° C. to about 700° C. which ishigher than the temperature of a bath exit, and the temperature of thebath exit is maintained in the range of about 420° C. to about 500° C.which is lower than the temperature of the bath entrance, so that theintermediate wire rod is plated with zinc.

The intermediate wire rod for the core wire 12 is plated with zinc atthe high temperature so that the intermediate wire rod can represent thetensile strength of about 500N/mm2 and the elongation percentage ofabout 5% or more.

In order to make the conditions for a soft wire, if the zinc dip-platingprocess is performed by dipping the core wire into the plating bath at ahigh temperature and passing the core wire through the plating bath, thecore wire is formed on the boundary surface thereof with the first alloylayer 22 including the copper-zinc ally due to the mutual diffusionreaction with zinc when the core wire is dipped into the melted zinc andpassed through the melted zinc, and the second alloy layer 23 includingthe zinc-copper alloy is formed on the outer portion of the first alloylayer 22 while forming a soft core wire.

The second alloy layer 23 including the zinc-copper alloy represents thehighest hardness and represents the elongation percentage significantlylower than that of the soft core wire.

Through the zinc dip-plating process and the mutual diffusion reaction,the first alloy layer 22 including the copper-zinc alloy is formed atthe thickness of about 1 full to about 3 μm on the boundary surface ofthe core wire 12, and the second alloy layer 23 including thezinc-copper alloy is formed at the thickness of about 3 μm to about 10μm on the outermost layer.

The first alloy layer 22 is formed due to the mutual diffusion reactionbetween the solid-phase core wire 12 and the liquid-phase melted zinc,and the second alloy layer 23 including zinc and copper is formed bybonding the liquid-phase melted zinc with the material of the core wire12 including the solid-phase first metal through the mutual diffusionreaction therebetween, so that the bonding strength with the core wirecan be increased.

The second alloy layer is significantly cracked when the intermediatewire rod including the first alloy layer 22, the second alloy layer 23,and the soft core wire 12 is subject to a fine wire (elongation)process, and the softer metal constituting the core wire is erupted ontothe surface of the second alloy layer 23, which is provided at theoutermost layer, through the gap between the cracks as if lava anddistributed on the surface of the second alloy layer 23.

The intermediate wire rod including the alloy layers is drawn, so thatthe intermediate wire rod is formed as a fine wire having a diameter ofabout 0.07 mm to about 0.35 mm.

Since the second alloy layer 23 of the drawn fine wire represents higherhardness and lower elongation percentage as compared with the core wire12, cracks significantly appear on the surface of the outermost layercorresponding to the second alloy layer 23 when the fine wire is formedthrough the drawing process, and the second alloy layer 23 forms aninterfacial surface together with the first metal constituting the corewire 12 while interposing the first alloy layer 22 between the secondalloy layer 23 and the first metal of the core wire 12.

Grains having the compositional ratio of three components of the firstmetal of the core wire, the metallic component of the first alloy layerincluding the copper-zinc alloy layer, and the metallic component of thesecond alloy layer including the zinc-copper alloy layer are formed onthe surface of the electrode wire for electro-discharge machining thathas been manufactured through the above method as shown in FIGS. 3 and9.

The electrode wire for electro-discharge machining that has beenmanufactured through the fine wire process is additionally subject to aheat treatment process within 0.05 second to three seconds at thetemperature of about 300° C. to about 600° C., so that the mechanicalproperty of the core wire can be stabilized.

Embodiment 2

A core wire (including the first metal) having a diameter of about 0.9mm, which is a brass wire (i.e., core wire including the first metal)having a compositional ratio of about 65 weight % of copper and about 35weight % of zinc, is prepared as an intermediate wire rod.

A zinc dip-plating process is performed with respect to the core wire byusing zinc which is the second metal.

The core wire used in the zinc dip-plating process is passed through analkaline degreasing bath so that the core wire is cleaned. Then, afterthe core wire is subject to an acidic washing process, the core wire iscleaned again and passes through an ammonium chloride flux bath.

When the wire including the first metal that has been subject to theflux treatment is dipped into an zinc dip-plating bath of the secondmetal and passed through the plating bath so that the wire is platedwith zinc, the intermediate wire rod for the core wire is dipped intothe plating bath for one second to ten seconds and passed through theplating bath in a state that the temperature of a bath entrance ismaintained in the range of about 555° C. to about 700° C. which ishigher than the temperature of a bath exit, and the temperature of thebath exit is maintained in the range of about 420° C. to about 500° C.which is lower than the temperature of the bath entrance, so that theintermediate wire rod is plated with zinc.

The intermediate wire rod for the core wire 12 is plated with meltedzinc at the high temperature so that the intermediate wire rod canrepresent the tensile strength of about 500N/mm2 and the elongationpercentage of about 5% or more.

In order to make the conditions for a soft wire, if the zinc dip-platingprocess is performed by dipping the core wire into the plating bath at ahigh temperature and passing the core wire through the plating bath, thecore wire is formed on the boundary surface thereof with the first alloylayer 22 including the copper-zinc ally due to the mutual diffusionreaction with zinc when the core wire is dipped into the melted zinc andpassed through the melted zinc, and the second alloy layer 23 includingthe zinc-copper alloy is formed on the outer portion of the first alloylayer 22 while forming a soft core wire.

The second alloy layer 23 including the zinc-copper alloy represents thehighest hardness and represents the elongation percentage significantlylower than that of the soft core wire.

Through the zinc dip-plating process and the mutual diffusion reaction,the first alloy layer 22 including the copper-zinc alloy is formed atthe thickness of about 1 μm to about 3 μm on the boundary surface of thecore wire 12, and the second alloy layer 23 including the zinc-copperalloy is formed at the thickness of about 3 μm to about 10 μm on theoutermost layer.

The first alloy layer 22 is formed due to the mutual diffusion reactionbetween the solid-phase core wire 12 and the liquid-phase melted zinc,and the second alloy layer 23 including zinc and copper is formed bybonding the liquid-phase melted zinc with the material of the core wire12 including the solid-phase first metal through the mutual diffusionreaction therebetween, so that the bonding strength with the core wire12 can be increased.

The intermediate wire rod including the first alloy layer, the secondalloy layer, and the soft core wire is passed through the twist unit 33between the roller 16′ of FIG. 2 and the drawing unit 14 before theintermediate wire rod is subject to a fine wire process (elongationprocess), so that the intermediate wire rod is curved in a zigzagpattern.

After the intermediate wire rod has been passed through the twist unit33 of curving the intermediate wire rod in a zigzag pattern as describedabove before the intermediate wire rod is formed as the fine wire, theintermediate wire rod is formed as a fine wire having a diameter ofabout 0.07 mm to about 0.35 mm through a drawing process.

In particular, according to the present embodiment, stress is applied tothe intermediate wire rod so that the intermediate wire rod is curved ina predetermined direction before the intermediate wire rod is drawn asthe fine wire. Accordingly, as shown in FIG. 7, cracks appear on thesecond alloy layer in a direction perpendicular to a longitudinaldirection of the intermediate wire rod, and core wire metal made of softbrass is erupted onto the surface of the second alloy layer along thecracks as if lava, so that a plurality of grain groups are formed on thesurface of the second alloy layer.

Core wire materials including brass are significantly distributed ontothe surface of the electrode wire for electro-discharge machiningthrough the stress process of curving the intermediate wire rod, andbrass grains are arranged on the surface of the electrode wire in thecircumferential direction while forming a predetermined pattern. Thelength of the brass grain is twice to ten times greater than the widthof the brass grain.

Grain fragments having the compositional ratio of three components ofthe first metal of the core wire, the metallic component of the firstalloy layer including the copper-zinc alloy layer, and the metalliccomponent of the second alloy layer including the zinc-copper alloylayer are formed on the surface of the electrode wire forelectro-discharge machining that has been manufactured through the abovemethod as shown in FIGS. 4 and 10.

The electrode wire for electro-discharge machining that has beenmanufactured through the fine wire process is additionally subject to aheat treatment process within 0.05 second to three seconds at thetemperature of about 300° C. to about 600° C., so that the mechanicalproperty of the core wire can be stabilized.

Embodiment 3

A core wire (including the first metal) having a diameter of about 0.9mm, which is a brass wire (i.e., core wire including the first metal)having a compositional ratio of about 65 weight % of copper and about 35weight % of zinc, is prepared as an intermediate wire rod.

A zinc-electroplating process is performed with respect to the core wireby using zinc which is the second metal.

After the core wire used in the zinc-electroplating process has beenpassed through the alkaline cleaning bath, the core wire is subject tocleaning and acidic washing processes. Then, after the core wire issubject to the cleaning process again, the core wire is passed through azinc-electroplating bath.

The intermediate wire rod, which has been subject to thezinc-electroplating process, is put into heat treatment machine andsubject to a heat treatment process at the speed of about 155 m/minunder the voltage in the range of about 50V to about 60V. Accordingly,the core wire is formed with the tensile strength of about 500N/mm2 orless and the elongation percentage of about 5% or more.

If the heat treatment process is performed after the electroplatingprocess in order to fabricate an intermediate wire rod having the corewire satisfying the above conditions, the first alloy layer 22 includingcopper-zinc is formed on the boundary surface between the core wire(including the first metal) and the second metal, which is platedthrough the zinc-electroplating process, due the mutual diffusionreaction between the core wire and the second metal, and the secondalloy layer 23 including zinc-copper is formed at the outer portion ofthe first alloy layer 22.

The second alloy layer including zinc-copper represents the highesthardness and represents the elongation percentage lower than that of thesoft core wire.

Through the zinc-electroplating process and the mutual diffusionreaction, a first alloy layer including copper-zinc is formed at thethickness of about 1 μm to about 3 μM on the boundary surface of thecore wire, and the second alloy layer including zinc-copper is formed atthe thickness of about 3 gill to about 10 μm on the outer portion of thefirst alloy layer 23.

The first alloy layer is formed due to the mutual diffusion reactionbetween the first metal of the core wire and zinc (i.e., the secondmetal) plated in the electroplating process, and the second alloy layeris formed by diffusing the first metallic component constituting thecore wire to the second metal plated in the zinc-electroplating process,so that the core wire becomes in a soft wire state representing thetensile strength of about 500N/mm2 or less and the elongation percentageof about 5% or more.

In the intermediate wire rod, which is obtained by forming the first andsecond alloy layers on the core wire, cracks significantly appear on thesecond alloy layer representing the highest hardness, and the softermetal constituting the core wire is erupted onto the surface of thesecond alloy layer corresponding to the outermost layer along the gapbetween cracks as if lava and distributed onto the surface of the secondalloy layer.

The intermediate wire rod having the alloy layers is formed as a finewire having a diameter of about 0.07 mm to about 0.35 mm through adrawing process.

Since the second alloy layer of the drawn fine wire represents thehigher hardness and the lower elongation percentage, a great amount ofcracks appear on the surface of the outmost layer corresponding to thesecond alloy layer when the fine wire is formed through the drawingprocess. The second alloy layer forms an interfacial surface togetherwith the first metal while interposing the first alloy layer between thesecond alloy layer and the first metal.

Grain fragments having the compositional ratio of three components ofthe first metal of the core wire, the metallic component of the firstalloy layer including the copper-zinc alloy layer, and the metalliccomponent of the second alloy layer including the zinc-copper alloylayer are formed on the surface of the electrode wire forelectro-discharge machining that has been manufactured through the abovemethod as shown in FIGS. 5 and 9.

The electrode wire for electro-discharge machining that has beenmanufactured through the fine wire process is additionally subject to aheat treatment process within 0.05 second to three seconds at thetemperature of about 300° C. to about 600° C., so that the mechanicalproperty of the core wire can be stabilized.

Embodiment 4

A core wire (including the first metal) having a diameter of about 0.9mm, which is a brass wire (i.e., core wire including the first metal)having a compositional ratio of about 65 weight % of copper and about 35weight % of zinc, is prepared as an intermediate wire rod.

A zinc-electroplating process is performed with respect to the core wireby using zinc which is the second metal.

After the core wire used in the zinc-electroplating process has beenpassed through the alkaline cleaning bath, the core wire is subject tocleaning and acidic washing processes. Then, after the core wire issubject to the cleaning process again, the core wire is passed through azinc-electroplating bath.

The intermediate wire rod, which has been subject to thezinc-electroplating process, is put into heat treatment machine andsubject to a heat treatment process at the speed of about 155 m/minunder the voltage in the range of about 50V to about 60V. Accordingly,the core wire is formed with the tensile strength of about 500N/mm2 orless and the elongation percentage of about 5% or more.

If the heat treatment process is performed after the electroplatingprocess in order to fabricate an intermediate wire rod satisfying theabove conditions, the first alloy layer 22 including copper-zinc isformed on the boundary surface between the core wire (including thefirst metal) and the second metal, which is plated through thezinc-electroplating process, due the mutual diffusion reaction betweenthe core wire and the second metal, and the second alloy layer 23including zinc-copper is formed at the outer portion of the first alloylayer 22.

The first alloy layer is formed due to the mutual diffusion reactionbetween the first metal of the core wire and zinc (i.e., the secondmetal) plated in the electroplating process, and the second alloy layeris formed by diffusing the first metallic component of the core wire tothe second metal used in the zinc-electroplating process, so that thecore wire becomes in a soft wire state representing the tensile strengthof about 500N/mm2 or less and the elongation percentage of about 5% ormore.

The second alloy layer including zinc-copper represents the highesthardness and represents the elongation percentage lower than that of thesoft core wire.

Through the heat treatment process after the electroplating process, thefirst alloy layer including the alloy of copper-zinc is formed at thethickness of about 1 μm to about 3 μm on the boundary surface of thecore wire, and the second alloy layer including the zinc-copper alloy isformed at the thickness of about 3 μm to about 10 μm on the outermostlayer.

The intermediate wire rod including the first alloy layer, the secondalloy layer, and the soft core wire is passed through the twist unit 33between the roller 16′ of FIG. 2 and the drawing unit 14 before theintermediate wire rod is subject to a fine wire process (elongationprocess), so that the intermediate wire rod is curved in a zigzagpattern.

After the intermediate wire rod has been passed through the twist unit33 of curving the intermediate wire rod in a zigzag pattern before theintermediate wire rod is formed as a fine wire, the intermediate wirerod is formed as a fine wire having a diameter of about 0.07 mm to about0.35 mm through a drawing process.

In particular, according to the present embodiment, stress is applied tothe intermediate wire rod so that the intermediate wire rod is curved ina predetermined direction before the intermediate wire rod is drawn asthe fine wire. Accordingly, as shown in FIG. 8, cracks additionallyappear on the second alloy layer in a direction perpendicular to alongitudinal direction of the intermediate wire rod, and core wire metalmade of soft brass is erupted onto the surface of the second alloy layerthrough the cracks as if lava, so that a plurality of grain groups areformed on the surface of the second alloy layer.

Core wire materials including brass are significantly distributed ontothe surface of the electrode wire for electro-discharge machining due tothe stress process of curving the intermediate wire rod, and brassgrains are arranged on the surface of the electrode wire in thecircumferential direction while forming a predetermined pattern. Thelength of the brass grain is twice to ten times greater than the widthof the brass grain.

Grain having the compositional ratio of three components of the firstmetal of the core wire, the metallic component of the first alloy layerincluding the copper-zinc alloy layer, and the metallic component of thesecond alloy layer including the zinc-copper alloy layer are formed onthe surface of the electrode wire for electro-discharge machining thathas been manufactured through the above method as shown in FIGS. 6 and10.

The electrode wire for electro-discharge machining that has beenmanufactured through the fine wire process is additionally subject to aheat treatment process within 0.05 second to three seconds at thetemperature of about 300° C. to about 600° C., so that the mechanicalproperty of the core wire can be stabilized.

As described above, according to the embodiments, since grains, whichsurround the second alloy layer, are formed by erupting the softer corewire upward onto the surface of the electrode wire through the cracksand exposing the core wire onto the surface of the electrode wire, asmall amount of machining particles are derived from the electrode wire.In addition, since the second alloy layer having a vaporizationtemperature lower than that of the first metal increases instantaneousvaporization power of thermal energy in discharging, the manufacturingspeed is increased, and the surface roughness of the workpiece and themanufacturing speed are maximized in the electro-discharging process.

The embodiments have been described in terms of the electroplatingprocess and the dip-plating process. However, even if a heat treatmentprocess may be performed after a chemical plating scheme has beenperformed, the same effects can be made.

The first metal may include copper or the alloy of copper other thanbrass, and the second metal may include zinc, aluminum, tin, or thealloy thereof.

Although a preferred embodiment of the present invention has beendescribed for illustrative purposes, those skilled in the art willappreciate that various modifications, additions and substitutions arepossible, without departing from the scope and spirit of the inventionas disclosed in the accompanying claims.

What is claimed is:
 1. An electrode wire for electro-dischargemachining, the electrode wire comprising: a core wire including a firstmetal; a first alloy layer formed at a boundary region between the corewire and a second metal plated on an outer surface of the core wire dueto mutual diffusion between the core wire and the second metal; and asecond alloy layer formed at an outer portion of the first alloy layerdue to diffusion of the first metal to the second metal, wherein a corewire material is erupted onto a surface of the electrode wire forelectro-discharge machining, which includes at least the core wire, thefirst alloy layer, and the second alloy layer, along cracks appearing onthe second alloy layer, so that a plurality of grains are formed on thesurface of the electrode wire, and wherein the grain including at leastthe core wire material and a second alloy material is distributed ontothe surface of the electrode wire for electro-discharge machining. 2.The electrode wire of claim 1, wherein the core wire material is eruptedtogether with a first alloy material, so that the grain including thecore wire material, the first alloy material, and the second alloymaterial is distributed on the surface of the electrode wire forelectro-discharge machining.
 3. The electrode wire of claim 1, whereinthe first metal includes one selected from the group consisting ofcopper, brass, and a copper alloy, and the second metal includes oneselected from the group consisting of zinc, aluminum, tin, and an alloythereof.
 4. The electrode wire of claim 1, wherein the grain includingat least the second alloy material is surrounded by the core wirematerial.
 5. The electrode wire of claim 1, wherein the grain includingthe core wire material is arranged in a direction substantiallyperpendicular to a longitudinal direction of the electrode wire forelectro-discharge machining, and has a length twice or ten times greaterthan a width of the grain.
 6. A method of manufacturing an electrodewire for electro-discharge machining, the method comprising: preparingan intermediate wire rod, which includes a first metal and has a firstdiameter, as a core wire; plating the core wire with a second metal;performing a heat treatment process to make the plated core wirerepresenting tensile strength of about 500 N/mm2 or less and elongationpercentage of 5 or more and to form a first alloy layer in at least aboundary region between the core wire and the second metal due to mutualdiffusion between the core wire and the second metal and to form asecond alloy layer on an outer portion of the first alloy layer throughdiffusion of the first metal to the second metal; and forming a grainincluding at least a core wire material and a second alloy material on asurface of the electrode wire for electro-discharge machining byerupting the core wire material through a crack appearing on the secondalloy layer when performing a fine wire process of making the electrodewire for electro-discharge machining which includes the first alloylayer, the second alloy layer, and the core wire and has a seconddiameter.
 7. The method of claim 6, wherein, in the forming of the grainon the surface of the electrode wire for electro-discharge machining,the core wire material is erupted together with a first alloy material,so that the grain including the core wire material, the first alloymaterial, and the second alloy material is formed.
 8. The method ofclaim 6, wherein the core wire is plated with the second metal throughone of an electroplating scheme, a dip-plating scheme, and a chemicalplating scheme.
 9. The method of claim 8, wherein the core wire isplated with the second metal through the dip-plating scheme, and theheat treatment process is performed by dipping the core wire into aplating bath having an entrance temperature of about 550° C. to about700° C. and an exit temperature of about 420° C. to about 500° C. withintime of about 1 second to about 10 seconds.
 10. The method of claim 6,wherein, before the electrode wire for electro-discharge machining isdrawn to have a second diameter in the forming of the grain, theelectrode wire for electro-discharge machining is forcibly twisted in atleast one of up, down, left, and right directions.
 11. The method ofclaim 6, wherein the first metal includes one selected from the groupconsisting of copper, brass, and a copper alloy, and the second metalincludes one selected from the group consisting of zinc, aluminum, tin,and an alloy thereof.
 12. The electrode wire of claim 2, wherein thefirst metal includes one selected from the group consisting of copper,brass, and a copper alloy, and the second metal includes one selectedfrom the group consisting of zinc, aluminum, tin, and an alloy thereof.13. The electrode wire of claim 2, wherein the grain including at leastthe second alloy material is surrounded by the core wire material. 14.The electrode wire of claim 2, wherein the grain including the core wirematerial is arranged in a direction substantially perpendicular to alongitudinal direction of the electrode wire for electro-dischargemachining, and has a length twice or ten times greater than a width ofthe grain.
 15. The method of claim 7, wherein the core wire is platedwith the second metal through one of an electroplating scheme, adip-plating scheme, and a chemical plating scheme.
 16. The method ofclaim 7, wherein, before the electrode wire for electro-dischargemachining is drawn to have a second diameter in the forming of thegrain, the electrode wire for electro-discharge machining is forciblytwisted in at least one of up, down, left, and right directions.
 17. Themethod of claim 7, wherein the first metal includes one selected fromthe group consisting of copper, brass, and a copper alloy, and thesecond metal includes one selected from the group consisting of zinc,aluminum, tin, and an alloy thereof.